Additive Manufactured Mold With Double Deck Porous Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional molds for manufacturing molded fiber products are laborious to produce, limited in complexity, prone to clogging, and result in lower quality products due to surface markings and roughness.
Innovation Solution
A mold with a porous product surface created via additive manufacturing, featuring a double deck structure with a porous first layer and a perforated second layer, allowing for efficient drainage and cleaning, and enabling the production of high-quality, complex molded fiber products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining methods are used to manufacture molds, then manufacturing precision can be achieved, but the manufacturing process is laborious and complex structures cannot be produced
Solution Approach 1:
The patent replaces traditional mechanical machining methods with additive manufacturing technology. The mold is produced by selectively sintering powdery material using a laser beam, which allows complex three-dimensional structures to be built layer by layer without the limitations of conventional machining. This substitution enables the creation of intricate channel networks and porous structures that would be impossible to machine from solid material.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive machining to additive sintering. By using selective laser sintering of powder materials with controlled particle sizes (1-50 microns), the process can create complex internal geometries and porous structures directly. The wall thickness and channel dimensions are controlled by powder layer thickness and laser parameters rather than tool paths.
2Reliability
If through holes are made in the mold wall for permeability, then drainage function is achieved, but the holes are too big which causes clogging
Solution Approach 1:
The patent employs porous materials with controlled pore sizes of 1-50 microns throughout the mold structure. This porous architecture provides numerous small drainage pathways that prevent clogging while maintaining effective water removal. The porous structure is created during additive manufacturing by controlling powder packing and sintering parameters, resulting in a network of interconnected pores that are too small to clog but sufficient for drainage.
Solution Approach 2:
The patent transitions from two-dimensional through-holes to three-dimensional porous networks. Instead of discrete holes penetrating the mold wall, the additive manufacturing process creates a volumetric porous structure with channels extending in multiple directions throughout the mold body. This three-dimensional network provides redundant drainage paths that prevent clogging.
3Strength
If extra metal mesh is added to the product surface, then structural strength is improved, but marks remain on the product surface even after hot pressing
Solution Approach 1:
The patent uses composite materials consisting of cellulose fibers suspended in water or foam. The fiber network forms a natural reinforcement structure within the molded product, providing structural strength without requiring additional metal mesh. The fiber composite material itself creates the structural integrity needed for disposable tableware applications.
Solution Approach 2:
The patent removes the metal mesh component entirely from the manufacturing process. Instead of adding external reinforcement that causes surface marks, the design relies on the inherent structural properties of molded fiber materials. The extraction of problematic metal mesh eliminates the source of surface defects while maintaining product strength through optimized fiber formulation and molding parameters.
4Productivity
If the mold is made with a porous surface for drainage, then water removal is improved, but the mold becomes rough and suitable only for lower quality products
Solution Approach 1:
The patent segments the mold surface into distinct functional zones with different pore characteristics. The product-facing surface has controlled porosity optimized for water removal, while separate drainage channels and evacuation paths are created in the mold structure. This segmentation allows the porous surface to efficiently drain water without transferring roughness to the product, as the pore structure is confined to the mold material rather than imprinted on the product.
Solution Approach 2:
The patent applies local quality by giving different regions of the mold different pore sizes and distributions. The product contact surface has fine, controlled porosity that removes water without creating marks, while internal drainage channels have larger openings for efficient water evacuation. This localized optimization allows simultaneous achievement of high water removal efficiency and smooth product surface quality.
5Productivity
If traditional molds are used for fiber slurry, then manufacturing process is established, but the process is laborious and product changes are slow
Solution Approach 1:
The patent introduces dynamics by making the mold design adaptable and reconfigurable. The additive manufacturing process allows rapid prototyping and production of different mold geometries for various product designs. Channel configurations, pore distributions, and mold cavity shapes can be easily modified by changing digital models and reprinting, enabling quick adaptation to different fiber slurry formulations and product requirements without retooling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The mold is easier and quicker to manufacture, allows for faster product changes, reduces production costs, and produces high-quality, smooth molded fiber products with improved drainage and cleaning capabilities.
Implementation Method 1
Porous means in this application minute interstices through which liquid, air or steam may pass
Implementation Method 2
minute interstices through which liquid, air or steam may pass via various undefined routes
Implementation Method 3
an additive manufacturing process such as a 3D-printing process. Such an additive manufacturing process may comprise selective sintering of a powdery material having particles of an average size of 1 - 50 microns
Implementation Method 4
the powdery material is completely melted through the addition of energy by means of a laser beam
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a mold for manufacturing of a molded fiber product. The mold (11) includes a porous product surface (23) made by additive manufacturing. The product surface (23) is arranged as a double deck structure (40) including two layers (41, 42). Between the layers (41, 42) there is a cavity (43) wherein the first layer (41) has porousness from the cavity (43) to the product surface (23). The second layer (42) has perforations isolated from the cavity (43) and extending from the product surface (23) through the double deck structure (40).